Lithium manganese iron phosphate (lmfp) batteries, systems, and methods

Abstract

Lithium manganese iron phosphate (LMFP) batteries, systems, and methods. Lithium manganese iron phosphate (LMFP) battery systems, cells, and methods configured to smooth the step-like voltage behavior inherent to the LMFP chemistry are disclosed. The present disclosure describes blending LMFP cathode materials with different iron to manganese ratios to moderate the multi-phase redox reactions, resulting in more ramped voltage profiles during charge and discharge. Blending cathode materials can be integrated at the material level, electrode level, cell level, or battery pack level to improve state-of-charge estimation, power control, and battery management system performance while maintaining the inherent safety, cost, and cycle life advantages of the LMFP chemistry. The disclosed systems support a modular battery architecture suitable for electric vehicles, heavy-duty applications, and stationary energy storage. By reducing the steep voltage jumps without introducing higher risk chemistries, the disclosed approach enables improved controllability, reliability, and scalability of LMFP-based energy storage systems.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 755,871, filed February 7, 2025, entitled “Lithium Manganese Iron Phosphate (LMFP) Battery System for Heavy Duty Applications,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to energy storage systems for electric vehicles (EVs). Specifically, it relates to the design, composition, and integration of lithium manganese iron phosphate (LMFP) batteries for EV applications to improve performance, safety, and sustainability. Background Technology

[0004] Driven by the demand for sustainable transportation, the adoption of electric vehicles (EVs) has increased significantly. Lithium-ion batteries (LIBs) dominate the EV market due to their high energy density and efficiency. However, existing LIB chemistry systems, such as lithium nickel manganese cobalt oxide (NMC) and lithium iron phosphate (LFP), face challenges in balancing cost, thermal stability, energy density, and sustainability.

[0005] LMFP batteries offer a promising solution by combining the inherent thermal stability of LFPs with the increased energy density imparted by manganese doping. Despite these advantages, the integration of LMFP batteries into EV systems remains limited due to challenges in optimizing material synthesis, electrode design, and vehicle-level management systems. Summary of the Invention

[0006] This disclosure presents a novel LMFP battery system tailored for EVs. This system addresses key challenges through advancements in cathode material composition, cell architecture, thermal management, and battery management system (BMS). The system offers a range of significant advantages, including improved energy density through optimized synthesis of the LMFP cathode material, making it competitive with NMC chemistry systems. The system delivers extended cycle life and improved calendar stability through advanced doping techniques and precise electrode formulation. Excellent thermal properties ensure superior stability, significantly reducing the risk of thermal runaway and enhancing overall safety. Cost-effectiveness is another key benefit, as the system minimizes reliance on expensive materials such as cobalt and nickel, promoting sustainability and reducing production costs. Additionally, the system's modular design allows for seamless scalability, enabling integration into a variety of electric vehicle platforms.

[0007] The principle of this disclosure lies in using co-blended LMFPs to smooth the steep discharge voltage of LMFP batteries. This approach retains the advantages of the LMFP chemistry system, such as low cost, high safety performance, and long cycle life. Attached Figure Description

[0008] Figure 1A and Figure 1B This is a graph showing various discharge curves of LMFP cells with different Mn:Fe ratios; Figure 2A and Figure 2B These are diagrams illustrating several scenarios in which the principles of this disclosure can be applied; and Figures 3A to 3C It is a flowchart of a method based on the principles of this disclosure, wherein Figures 3A to 3C include Figure 3A The first part of the flowchart shown and Figure 3B The second part of the flowchart shown.

[0009] Figure 4 This is a schematic diagram of an example electrified vehicle system incorporating a battery pack constructed according to the principles of this disclosure. Detailed Implementation

[0010] The LMFP battery devices, systems, and methods disclosed herein utilize advanced materials and manufacturing technologies to optimize performance and reliability. At their core, the positive and negative electrodes form the fundamental components of the battery. The positive electrode is the primary electrode and serves as the lithium-ion source during discharge. This positive electrode is designed to accommodate manganese, iron, and phosphate in a uniform distribution to maximize capacity and cycle life. Nanostructuring the positive electrode increases its surface area, promotes faster ion transport, and reduces charge transfer resistance, making it suitable for high-rate applications. The positive electrode material is synthesized via a co-precipitation method, ensuring a consistent composition that improves stability and lifespan.

[0011] On the other hand, the negative electrode is the negative electrode of the battery and acts as a receiver of lithium ions during discharge. The principles of this disclosure are applicable to lithium-ion batteries with different negative electrode materials (such as graphite, silicon, lithium metal, etc.). (For example, Figure 1A and Figure 1B The results in this study show that graphite was used as the negative electrode for collection. This composition allows the battery to achieve a balance between energy density and cycle life. In this system, an electrolyte with stabilizing additives forms a solid electrolyte interphase (SEI) film on the negative electrode to protect it from degradation and improve thermal properties.

[0012] The cathode material is synthesized through a high-temperature solid-state reaction, in which the precursor is calcined in a controlled environment to obtain the desired crystal structure. The particles are coated with conductive carbon to improve electron transport and durability. Additionally, doping with elements such as magnesium or zirconium enhances the structural integrity of the material, enabling it to withstand repeated charge and discharge cycles without significant degradation.

[0013] Electrode fabrication integrates these materials into a single system. Active materials are mixed with conductive additives and binders to form a slurry, which is then uniformly applied to the current collector. This ensures consistent thickness and minimal defects. After drying and rolling, the electrodes are assembled into battery cells that can be cylindrical, prismatic, or pouch-shaped, depending on the application requirements.

[0014] Thermal management in battery systems is crucial for maintaining operational safety and efficiency. A thermal management system (TMS) incorporates phase change materials to absorb excess heat in high-demand scenarios, while a liquid cooling system ensures uniform heat distribution throughout the battery pack. Embedded thermal sensors provide real-time data to the battery management system (BMS), which dynamically adjusts its operation to optimize thermal performance.

[0015] Battery Management System (BMS) is a complex control system that monitors and manages the state of charge (SOC) and state of health (SOH) of a battery. Using advanced algorithms, BMS can predict performance trends and detect potential problems, ensuring that the battery remains under safe operating conditions. Active cell balancing within the BMS extends the overall lifespan of the system by equalizing the charge on all cells, preventing overcharging and undercharging.

[0016] To ensure compatibility with various electric vehicle platforms, the battery pack is designed to be modular. Each module is self-contained with its own control system, allowing for scalability to meet different energy and power requirements. This modular approach simplifies maintenance and recycling, improving the sustainability of the entire system.

[0017] Electrolyte formulation is a key aspect of battery performance. High-voltage electrolytes, enhanced with advanced additives, stabilize the positive electrode interface and prevent decomposition at elevated voltages. This extends the battery's operating range and improves energy density without compromising safety. The separator, chosen for its thermal stability and low resistance, enhances safety by promoting efficient ion transport while preventing internal short circuits.

[0018] Integrating LMFP batteries into electric vehicles requires standardizing the interface and ensuring compatibility with existing charging infrastructure. This battery supports fast charging, reducing downtime for vehicle owners. Furthermore, the system's inherent resistance to thermal runaway provides an additional layer of safety due to its stable crystal structure and high decomposition temperature.

[0019] Rigorous quality control during manufacturing ensures high reliability. Each cell undergoes comprehensive testing for capacity, impedance, and thermal stability. Automated inspection systems identify and resolve potential defects, ensuring consistent performance across all manufacturing units.

[0020] Sustainability is the cornerstone of LMFP battery systems. By minimizing the use of cobalt and nickel, the environmental and ethical issues associated with their extraction are reduced. The relatively simple composition of LMFP materials facilitates recycling, enabling the efficient recovery of critical components such as lithium, manganese, and iron.

[0021] The LMFP battery system represents a revolutionary advancement in energy storage technology for electric vehicles. By addressing the limitations of existing lithium-ion batteries, this system paves the way for safer, more efficient, and sustainable transportation solutions. Every component, from the positive and negative electrodes to the electrolyte and thermal management system, is meticulously designed to meet the demanding requirements of modern electric vehicles, setting a new benchmark in performance and reliability.

[0022] The LMFP battery chemistry system meets the needs of next-generation solutions due to its superior properties, such as cost-effectiveness, robust safety profile, and outstanding long lifespan. These qualities make LMFP a promising candidate for addressing the growing demand for advanced energy storage systems.

[0023] This disclosure relates to smoothing the stepped voltage in LMFP technology using blended cathode materials. More specifically, this disclosure relates to smoothing the steep voltage jumps in LMFP batteries by blending different LMFP cathode materials in various proportions. Voltage jumps in LMFP batteries are a decisive feature for enhancing their operational stability and efficiency. During charge and discharge cycles, lithium ions jump between the negative and positive electrodes via a series of voltage plateaus controlled by the redox reactions of manganese and iron within the cathode material. These jumps occur at different voltage levels due to the multi-electron processes involved, thus providing a stable energy delivery profile. The presence of manganese increases the operating voltage range, while iron ensures cost-effectiveness and structural durability. This balance allows LMFP batteries to achieve higher energy densities without compromising cycle life. Additionally, stable voltage jumps reduce stress on the electrolyte, minimizing degradation and extending battery life.

[0024] However, the stepped nature of the voltage profile poses a significant challenge in practical applications. This distinct voltage behavior complicates accurate SOC monitoring and precise power output control. For battery engineers, a smoother, more sloping voltage profile is highly desirable, as it facilitates the development of a more efficient BMS, enabling improved operational control and reliability.

[0025] To address this issue, the concept of blending LMFPs with nickel manganese cobalt (NMC) has been proposed to smooth abrupt voltage jumps. Despite these efforts, the characteristic stepped voltage profile remains evident. Furthermore, incorporating NMC into the blend introduces additional trade-offs, including reduced safety performance, shorter cycle life, and increased production costs. These challenges underscore the need for further innovation and optimization to fully realize the potential of LMFP cells while mitigating these limitations.

[0026] Figure 1A and Figure 1B This diagram shows several discharge curves of LMFP cells for different chemical systems, including Mn-Fe ratios of 5:5, 6:4, and 7:3, and mixed variants of these materials, such as blends of 1:1, 1:2, 2:1, 3:1, and 1:3. Although discharge curves for 6:4 and 5:5 are shown, LMFP cells with Mn-Fe ratios of 7:3 and 6:4 can be envisioned and considered as evaluation candidates. The voltage curves for the blended LMFP cathodes are based on simulations of the voltages of single-phase LMFPs and are for illustrative purposes only.

[0027] Therefore, this disclosure relates to using blended LMFPs with different Mn-Fe ratios to smooth the voltage profile. This will offset the problem of steep abrupt changes in the two-phase voltage profile, which poses challenges in SOC estimation and power control associated with this technology. The blended LMFP comprises at least two materials with different Mn-Fe ratios. For example, these materials can be selected from groups of Mn-Fe ratios of 5:5, 6:4, 7:3, or other similar ratios. By adjusting the proportions of different LMFP cathode materials with different Mn-Fe ratios, the LMFP voltage profile can be significantly smoothed, which will be beneficial for battery control in practical applications. Advantageously, the blended LMFP will retain the advantages of LMFP cathode materials, such as low cost, high safety, and long cycle life.

[0028] The voltage profile of the blended LMFP cathode is based on a simulation of the voltage of a single-phase LMFP and is for illustrative purposes only. The actual voltage profile is expected to be more sloping. It is conceivable that blending three-phase, four-phase, or even more LMFP phases will further smooth the voltage profile and facilitate battery control.

[0029] LMFP batteries are particularly useful in heavy-duty applications due to their excellent thermal stability, long cycle life, and high energy density. These characteristics make them well-suited for harsh environments such as commercial vehicles, industrial machinery, and grid-scale energy storage systems. LMFP batteries can withstand high discharge rates and maintain performance under heavy loads, ensuring long-term reliable power delivery. Additionally, their inherent safety features, such as resistance to thermal runaway, provide an extra layer of protection under harsh and high-stress operating conditions, making them a reliable choice for heavy-duty applications.

[0030] Figure 2A and Figure 3B Various scenarios in which the principles of this disclosure can be implemented are illustrated. In particular, Figure 2A Scenario A and Scenario B are shown, corresponding to the material level and the battery cell component level, respectively. Figure 2B Scenario C is shown, corresponding to the single-cell battery level. Each of these scenarios will be discussed in more detail below. Note that although these figures illustrate the first and second cathode materials with Fe-Mn ratios of 6:4 and 5:5, it is conceivable that these scenarios could be employed using any Fe-Mn ratio discussed elsewhere in this document.

[0031] Scenario A - Material Level

[0032] The process of forming materials for batteries involves several useful steps, each contributing to the overall performance, durability, and safety of the final battery cell. The materials illustrated are: LMFP cathode material 1 (Fe:Mn=6:4) and LMFP cathode material 2 (Fe:Mn=5:5). For example, cathode materials 6:4 and 7:3 can be used and validated in the laboratory. These steps include: mixing the materials to form a blend; coating an electrode with the blend; forming an electrode stack with the electrode; and integrating the electrode stack into the battery cell.

[0033] The initial step involves mixing active materials (such as positive or negative electrode components) with conductive additives and binders to produce a homogeneous blend powder. This step ensures a uniform material distribution, which is essential for consistent electrochemical performance. High-precision equipment, such as ball mills or high-shear mixers, is often used to obtain the desired particle size and distribution. The blend powder is then evaluated to verify its composition and confirm that it meets predetermined specifications.

[0034] In the next step, the blended powder is processed into a slurry by adding a suitable solvent. The slurry is then applied to the current collector (typically aluminum for the positive electrode and copper for the negative electrode) using techniques such as blade coating or slot extrusion coating. The coated electrodes are then dried to remove the solvent and subsequently rolled to achieve the desired thickness and density. This step helps ensure good contact between the active material and the current collector, which improves electron transport efficiency and overall efficiency.

[0035] The coated electrodes are then cut into specific shapes and layered to form electrode stacks. Depending on the battery design, this can involve stacking individual layers of the negative electrode, separator, and positive electrode in a specific order, or winding them into a cylindrical or square configuration. The separator plays a crucial role in preventing short circuits by electrically isolating the negative and positive electrodes while allowing ion movement between them. Precision in alignment and stacking helps verify uniform electrochemical reactions during operation.

[0036] Finally, the electrode stacks are encapsulated within a single battery cell housing, which can be cylindrical, square, or pouch-shaped. An electrolyte is introduced into the battery cell to promote ionic conductivity, and the cell is sealed using techniques such as heat sealing, press-fitting, or laser welding. The resulting battery cell undergoes an initial charging process, commonly known as a formation cycle, to activate the electrochemical materials and stabilize the solid electrolyte interphase (SEI) layer. Once formed, the battery cell undergoes a comprehensive evaluation to ensure it meets performance, safety, and quality standards before integration into a larger battery pack.

[0037] These steps together ensure the production of high-performance battery cells with the required energy density, cycle life, and safety characteristics.

[0038] Scenario B - Battery Cell Component Level

[0039] The cell-level mixing process for battery manufacturing focuses on precise assembly techniques to ensure optimal performance and safety of the final product. Key steps include forming electrode stacks and constructing the complete cell. The illustrated materials and components are as follows: LMFP cathode material 1 (Fe:Mn=6:4) and LMFP cathode material 2 (Fe:Mn=5:5), where the cell components are electrodes. For example, validation tests can be performed with ratios of 6:4 and 7:3. These steps include forming electrode stacks with two or more positive electrodes and integrating the electrode stacks into the cell.

[0040] The method for constructing a single battery cell begins with the selection and fabrication of two distinct positive electrode systems, each with a different chemical system, to optimize performance under various operating conditions. These positive electrode systems are designed to complement each other, leveraging the advantages of multiple active materials to improve energy density, cycle life, and overall stability.

[0041] Each positive electrode is manufactured using an independent composition of active materials, chosen to support different electrochemical properties. The first positive electrode may include high-energy-density materials, such as lithium nickel manganese cobalt oxide (NMC), to provide strong voltage stability and long-lasting discharge capacity. The second positive electrode may be composed of lithium manganese iron phosphate (LMFP), which is known to have excellent thermal stability and long cycle life.

[0042] The positive electrode is coated onto an aluminum current collector to ensure uniform material distribution. Then, for optimal ion transport and structural integrity, the electrode is rolled to obtain precise thickness and density.

[0043] The prepared positive electrode is bonded together with the corresponding negative electrode into an electrode stack, the negative electrode typically composed of graphite, silicon-carbon composite material, or other high-capacity materials. A separator is placed between each positive and negative electrode layer to prevent electrical short circuits while allowing efficient ion movement during charge and discharge cycles.

[0044] The electrode stacks are assembled in a repeating sequence to ensure consistent electrochemical action. The stacking process is achieved through an automated, precise layering technique, ensuring accurate alignment of all components. The structured electrode stacks are then compressed to enhance contact between layers, thereby improving conductivity and mechanical stability.

[0045] Once the electrode stack is formed, it is integrated into a battery housing designed for optimal safety and performance. This housing can be cylindrical, square, or pouch-shaped, depending on the intended application. An electrolyte, carefully selected to support both cathode chemistry systems and promote stable ion transport, is then introduced into the battery cell.

[0046] Battery cells are sealed using thermal welding or laser welding techniques to prevent contamination and ensure long-term reliability. A formation process is then applied, which includes controlled charge and discharge cycles to activate electrochemical reactions, stabilize the solid electrolyte interphase (SEI) layer, and ensure proper interaction between the cathodes in the dual-chemistry system.

[0047] Finally, before being integrated into battery modules and packs for commercial applications, the battery cell undergoes rigorous testing for capacity retention, thermal stability, and cycle efficiency. This approach allows for a balanced approach to energy storage, leveraging the advantages of multiple cathode chemistry systems to create high-performance lithium-ion battery cells.

[0048] Scenario C - Battery Cell Level

[0049] The hybridization process at the cell level involves assembling individual cell units into an integrated battery pack that meets specific energy and power requirements. This stage focuses on integrating cell units while ensuring optimal performance, safety, and compatibility with the intended application. The materials illustrated are: LMFP cathode material 1 (Fe:Mn=6:4) and LMFP cathode material 2 (Fe:Mn=5:5). These steps involve integrating both cell units with the first cathode material and cell units with the second cathode material into the battery pack.

[0050] Battery packs are formed from individual battery cells: The formation of a battery pack begins with arranging individual battery cells in a specific configuration (such as series, parallel, or a combination of both) according to the required voltage and capacity requirements. Conductive interconnects (such as busbars or solder tabs) are used to connect the battery cells to create electrical pathways that enable efficient energy transfer within the battery pack. This arrangement is carefully designed to minimize resistance and ensure balanced performance among all battery cells.

[0051] To maintain mechanical stability and thermal management, the battery cells are housed in a robust casing. This casing is typically constructed from materials such as aluminum or high-strength polymers to provide durability while minimizing weight. Thermal management systems, such as liquid cooling plates or radiators, are integrated into the battery pack to regulate temperature and prevent overheating during operation.

[0052] The Battery Management System (BMS) is installed as a component of the battery pack. The BMS monitors the State of Charge (SOC), State of Hypothesis (SOH), and temperature of each individual cell to ensure balanced operation and prevent overcharging or deep discharging. Advanced algorithms within the BMS enable dynamic adjustments to optimize the battery pack's performance and lifespan.

[0053] The final step involves sealing the battery pack to protect it from external environmental factors such as moisture, dust, and mechanical shock. The assembled battery pack undergoes a series of rigorous tests, including electrical performance evaluation, thermal assessment, and safety verification, to ensure it meets all quality and regulatory standards. Once approved, the battery pack can be integrated into electric vehicles, energy storage systems, or other applications, providing reliable and efficient power for a variety of uses.

[0054] By following these steps, manufacturers can produce efficient, durable, and customized battery packs to meet the needs of modern energy applications.

[0055] While these steps have been discussed in the context of LMFP batteries, similar approaches can be applied to other battery chemistry systems. For example, lithium nickel manganese cobalt oxide (NMC) or lithium iron phosphate (LFP) batteries can benefit from the same principles of precise cell arrangement, robust thermal management, and advanced battery management systems. Regardless of the chemistry, the fundamental processes of ensuring consistent cell performance, protecting the battery pack from environmental stressors, and integrating effective monitoring and control systems remain universal.

[0056] These methods not only improve battery pack performance and safety, but also offer flexibility in adapting to the unique characteristics and challenges of different chemical systems. By leveraging these shared technologies, manufacturers can develop customized solutions that meet the specific requirements of a wide range of applications, from electric vehicles to renewable energy storage.

[0057] Figures 3A to 3C This is the flowchart for example process 300. Figures 3A to 3C include Figure 3A The first part of the flowchart shown and Figure 3B The second part of the flowchart shown. In some embodiments, Figures 3A to 3C One or more process frames can be executed by a single battery cell.

[0058] like Figures 3A to 3C As shown, process 300 may include providing a first cathode material comprising a blend of multiple active materials, each of which contributes to a multiphase reaction with a variable reaction rate (box 302). For example, a battery cell may provide a first cathode material comprising a blend of multiple active materials, each of which contributes to a multiphase reaction with a variable reaction rate, as described above. Also as Figures 3A to 3C As shown, process 300 may include providing a second cathode material that is chemically compatible with the first cathode material, the second cathode material being similar to the first cathode material (box 304). For example, a battery cell may provide a second cathode material that is chemically compatible with the first cathode material, the second cathode material being similar to the first cathode material, as described above. Figures 3A to 3C As further shown, process 300 may include mixing the first cathode material and the second cathode material to form a blended cathode material (block 306). For example, a single battery cell may mix the first cathode material and the second cathode material to form a blended cathode material, as described above. Also as Figures 3A to 3C As shown, process 300 may include forming a battery cell structure (block 308) using the blended cathode material, which can be assembled into a battery cell. For example, the battery cell can be formed using the blended cathode material, as described above. Figures 3A to 3CAs further shown, process 300 may include assembling the battery cell structure into a battery cell such that the battery cell is operatively integrated into a battery pack, the battery pack being controllable to address potential differences in charge / discharge behavior between the first positive electrode material and the second positive electrode material (box 310). For example, the battery cell may be assembled into a battery cell such that the battery cell is operatively integrated into a battery pack, the battery pack being controllable to address potential differences in charge / discharge behavior between the first positive electrode material and the second positive electrode material, as described above.

[0059] Process 300 may include additional embodiments, such as any single embodiment or any combination of embodiments described below and / or combined with one or more other processes described elsewhere herein. In a first embodiment, the first cathode material and the second cathode material are various mixtures of lithium manganese iron phosphate (LMFP) materials.

[0060] In the second embodiment, either alone or in combination with the first embodiment, the first cathode material and the second cathode material are a blend of iron and manganese, wherein the first cathode material has a higher iron content than the second cathode material.

[0061] In the third embodiment, alone or in combination with the first and second embodiments, the multiphase reaction involves a first phase having a fast reaction rate or diffusion capability and a second phase having a slower, sustained reaction rate or diffusion capability.

[0062] In the fourth embodiment, alone or in combination with one or more of the first to third embodiments, the battery cell structure is an electrode, such that the step of forming a battery cell structure capable of being assembled into a battery cell using the blended positive electrode material includes integrating the blended positive electrode material into the electrode.

[0063] In the fifth embodiment, integrating the blended positive electrode material into the electrode, alone or in combination with one or more of the first to fourth embodiments, includes coating the electrode with the blended positive electrode material to form a coated electrode.

[0064] In the sixth embodiment, assembling the battery cell structure into a battery cell, either alone or in combination with one or more of the first to fifth embodiments, includes integrating the coated electrode into an electrode stack.

[0065] Although Figures 3A to 3C An example block diagram of process 300 is shown, but in some implementations, process 300 may include... Figures 3A to 3C The boxes depicted in the diagram may be fewer, different, or arranged differently compared to additional boxes. Alternatively, two or more boxes in process 300 may be executed in parallel.

[0066] In practice, this disclosure is applicable to EV manufacturers seeking cost-effective, safe, and sustainable battery solutions. LMFP battery systems support the increased adoption of EVs by addressing current limitations of LIB technology. Therefore, this invention provides an advanced LMFP battery system that balances energy density, safety, and cost for EV applications. By overcoming existing challenges, it paves the way for wider adoption and improved performance in sustainable transportation. Several practical examples are illustrated below, drawn based on some of the many principles discussed in this disclosure.

[0067] Overview of Electrified Vehicles

[0068] First see Figure 4 A schematic diagram of a battery electric vehicle 100 is provided. While the vehicle is referred to as a battery electric vehicle, it should be understood that the vehicle may alternatively be a hybrid vehicle, such as a plug-in hybrid vehicle, which is powered or otherwise operable via a battery and optionally one or more of a generator (e.g., an electric generator, generator set, power outlet, on-board rechargeable energy storage system, etc.) and a motor (e.g., an electric motor, traction motor, etc.). The battery electric vehicle 100 may operate in at least one of two directions: a reverse direction (e.g., rearward relative to the front of the vehicle) and a non-reverse direction (e.g., forward or at an angle relative to the front of the vehicle). The battery electric vehicle 100 may be an on-road vehicle or a non-on-road vehicle, including but not limited to passenger cars, trucks, ships, boats, vans, aircraft, spacecraft, or any other type of vehicle.

[0069] The battery electric vehicle 100 includes a powertrain controller 150 communicatively and operably coupled to a powertrain system 110, a braking mechanism 120, an accelerator pedal 122, one or more sensors (not shown), an operator input / output (I / O) device 135, and one or more additional vehicle subsystems 140. The battery electric vehicle 100 may include... Figure 4 The system components described herein, whether more, fewer, or different, make the principles, methods, and apparatus of this disclosure applicable to any suitable vehicle configuration. It should also be understood that the disclosed principles are not limited to highway vehicles. Rather, they can be applied to other applications, including but not limited to off-highway construction equipment, mining equipment, marine equipment, and locomotive equipment.

[0070] Powertrain system 110 facilitates the transmission of power from battery 132 and / or motor 113 to drive vehicle 100. In one embodiment, powertrain system 110 includes motor 113 operatively coupled to battery 132 and charging system 134, wherein motor 113 transmits power to final drive (e.g., wheels 115) to drive the vehicle. As shown, powertrain system 110 may also include transmission 112 and / or differential 114, wherein differential 114 transmits power output from transmission 112 to final drive 115. Powertrain controller 150 supplies power to motor 113 in response to inputs from accelerator 122, sensors, subsystem 140, and charging system 134 (e.g., battery charging system or rechargeable battery). In some embodiments, the electrical energy supplied to the power motor 113 may alternatively or additionally be provided by an onboard gasoline engine generator or hydrogen fuel cell.

[0071] In some embodiments, vehicle 100 includes a transmission 112, which can be configured as any transmission type compatible with the electrified powertrain, including continuously variable transmissions (CVTs), manual transmissions, automatic transmissions, automatic-manual transmissions, or dual-clutch transmissions. Transmission 112 can provide multiple gear ratios or continuously variable settings to determine the output speed based on engine or motor speed. Motor 113, differential 114, and final drive 115 can similarly take any configuration suitable for the vehicle type. In some instances, transmission 112 is omitted and motor 113 is directly coupled to differential 114; in other instances, motor 113 is directly coupled to final drive 115 in a direct drive configuration. Vehicle 100 may also include multiple instances of motor 113, such as one per driven wheel, one per driven wheel axle, or other suitable arrangements.

[0072] Braking mechanism 120 can be implemented as any system or device configured to prevent or reduce motion by slowing or stopping components of vehicle 100 (e.g., wheels, axles, crankshafts, or driveshafts). Braking mechanism 120 is typically configured to receive indication of a desired change in vehicle speed. In some embodiments, braking mechanism 120 includes a brake pedal operable by an operator of vehicle 100 between a released state and an applied state. The brake pedal can operate as a pressure-based system responsive to applied pressure or as a travel-based system responsive to pedal travel distance, wherein the force applied to braking mechanism 120 is proportional to the pressure or distance. In some embodiments, all or part of braking mechanism 120 is integrated into motor 113 as a regenerative braking mechanism.

[0073] The release state of the braking mechanism 120 corresponds to the brake pedal being in a default position where no braking is applied, for example, when the operator's foot is not on the pedal or is lightly placed below the minimum actuation force. In some embodiments, the brake pedal is combined with the accelerator pedal 122 in a one-pedal driving configuration. The applied state corresponds to pressing the pedal to achieve braking by satisfying or exceeding a minimum threshold force or travel distance. These thresholds prevent accidental actuation and can vary depending on the implementation, such as higher force for a foot-actuated brake pedal and lower force for a hand-actuated lever.

[0074] A decrease in actuation force or travel distance can correspond to an increase in desired vehicle speed, while an increase corresponds to a decrease in vehicle speed.

[0075] The accelerator pedal 122 can be any torque or speed request device, such as a floor pedal, joystick, or lever. Sensors associated with the accelerator 122 and / or braking mechanism 120 may include a vehicle speed sensor, an accelerator position sensor (e.g., a potentiometer), a brake position or pressure sensor, a coolant temperature sensor, a pressure sensor, an ambient air temperature sensor, or other suitable sensors.

[0076] Vehicle 100 may include an operator I / O device 135 that enables communication between the operator and powertrain controller 150. For example, device 135 may include an interactive display (e.g., a touchscreen) with buttons, haptic feedback, and controls for acceleration, braking, gear shifting, cruise control, or navigation. Via device 135, powertrain controller 150 may send instructions, commands, or status information to the operator.

[0077] Vehicle 100 also includes one or more vehicle subsystems 140, which may include sensors (e.g., speed, pressure, or temperature sensors) and additional systems such as torque sensors for motor 113, transmission 112, differential 114, and / or final drive 115. Other subsystems 140 may include a steering subsystem, an electrical subsystem, and a thermal management system, which includes a radiator, pump, fan, heat exchanger, and controller. Additional sensors may include cameras, LiDAR, RADAR, temperature sensors, smoke detectors, or virtual sensors.

[0078] The powertrain controller 150 is communicatively connected to the powertrain system 110, braking mechanism 120, accelerator 122, I / O device 135, and subsystem 140 via wired or wireless connections (e.g., CAN bus, fiber optic, Wi-Fi, Bluetooth, or cellular). The controller 150 receives and processes data and can interface with additional or alternative controllers as needed.

[0079] In embodiments including a charging system 134 (such as a plug-in charging system), when the charger 160 is connected to the vehicle 100, the powertrain controller 150 manages the charging of the battery 132. The charging controller 162 establishes communication between the controller 150 and the charger 160, receives charging commands, monitors sensor signals, and performs safety and performance checks. The charging controller 162 can detect faults such as connection failures or unsafe boundaries and serves as a communication interface between the charger 160 and the controller 150.

[0080] The powertrain controller 150 can also communicate with the charger 160, battery 132, and reporting accessory 164 (e.g., subsystem 140 or another component) via a CAN bus or other communication scheme. Reporting accessory 164 can transmit identification information, current demand, voltage consumption, and other operating parameters. Dynamic loads (e.g., air conditioning systems) can report variable current demands to optimize charging commands and avoid prolonged charging times due to insufficient current delivery.

[0081] Battery 132 includes one or more battery packs, each battery pack having a battery management system 166 and one or more battery modules 168. Sensors monitor temperature, voltage, and current to allow system 166 to manage charging, detect faults, and report conditions such as power limits and temperature to controller 150. Current sensors may be present inside or outside battery 132, and may include multiple sensors, with readings from these sensors summed to obtain the total current.

[0082] The powertrain controller 150 may include charging logic operable to determine commands for the charger 162 to supply a target current to the battery 132. This logic may reside within the controller 150, within the battery management controller 166, or in a separate controller. As used herein, the term "logic" encompasses hardware, firmware, or software that executes on one or more processors or integrated circuits. Such logic and instructions may be stored on a non-transitory machine-readable medium.

[0083] Transportation control systems and charging management systems can coordinate multiple chargers in a depot or fleet environment, managing vehicle arrival times, charging schedules, and grid load distribution to optimize cost and availability.

[0084] Although combined with the description of battery electric vehicles Figure 4 However, the disclosed architecture can also be applied to plug-in hybrid vehicles or other electrified powertrains that combine an internal combustion engine, transmission, and differential with battery propulsion.

[0085] For the purposes of this disclosure, the term "electrified vehicle" is used in an inclusive sense to refer to any vehicle that employs all or part of an electrical energy storage and propulsion system. Therefore, although combined... Figure 4 The embodiments described herein depict a battery electric vehicle 100; however, it should be understood that the same general system and control principles are equally applicable to hybrid electric vehicles, plug-in hybrid electric vehicles, fuel cell vehicles, or other architectures that integrate electric propulsion or energy storage with a mechanical power source. The term also covers configurations in which electrical components are used for auxiliary or regenerative functions in vehicles that are otherwise mechanically driven. Therefore, references to “battery electric vehicle” in the following description should not be construed as limiting. Rather, they are exemplary and represent a class of electrified vehicles to which the disclosed control systems, charging architectures, and subsystem integrations can be applied. Those skilled in the art will understand that similar functionality can be achieved in non-electrified or partially electrified systems where similar subsystems (such as powertrain controllers, charging controllers, or reporting accessories) exist.

[0086] In Example 1, a method for manufacturing a hybrid chemistry battery includes: providing a first cathode material comprising a blend of multiple active materials, each of which contributes to a multiphase reaction with a variable reaction rate; providing a second cathode material chemically compatible with the first cathode material, the second cathode material being similar to the first cathode material; mixing the first cathode material and the second cathode material to form a blended cathode material; forming a battery cell structure with the blended cathode material capable of being assembled into a battery cell; and assembling the battery cell structure into a battery cell such that the battery cell is operatively integrated into a battery pack, the battery pack being controllable to accommodate potential differences in charge / discharge behavior between the first cathode material and the second cathode material.

[0087] In Example 2, the method is as described in Example 1, wherein the first cathode material and the second cathode material are various mixtures of lithium manganese iron phosphate (LMFP) materials.

[0088] In Example 3, the method as described in any one of Examples 1 or 2, wherein the first cathode material and the second cathode material are a blend of iron and manganese, wherein the first cathode material has a higher iron content than the second cathode material.

[0089] In Example 4, the method as described in any one of Examples 1 to 3, wherein the multiphase reaction involves a first phase having a fast voltage curve and a second phase having a slower, sustained voltage curve.

[0090] In Example 5, the method of any one of Examples 1 to 4, wherein the cell structure is an electrode, the step of forming a cell structure capable of being assembled into a cell using the blended positive electrode material includes integrating the blended positive electrode material into the electrode.

[0091] In Example 6, the method as described in any one of Examples 1 to 5, wherein integrating the blended positive electrode material into the electrode includes coating the electrode with the blended positive electrode material to form a coated electrode.

[0092] In Example 7, a method as described in any one of Examples 1 to 6 is described, wherein assembling the battery cell structure into a battery cell includes integrating the coated electrode into an electrode stack.

[0093] In Example 8, a battery cell having a hybrid chemical system includes: a first positive electrode material comprising a blend of at least two active materials configured for a multiphase reaction having a variable discharge rate; a second positive electrode material designed to complement the chemical system of the first positive electrode material, the second positive electrode material being similar to the first positive electrode material; and an electrolyte promoting ionic conductivity between the positive and negative electrodes, the positive electrode comprising the first positive electrode material and the second positive electrode material.

[0094] In Example 9, the battery cell is as described in Example 8, wherein the first cathode material is a blended lithium manganese iron phosphate (LMFP) material.

[0095] In Example 10, the battery cell is as described in any one of Examples 8 or 9, wherein the first cathode material and the second cathode material are a blend of iron and manganese, wherein the first cathode material has a higher iron content than the second cathode material.

[0096] In Example 11, the battery cell as described in any one of Examples 8 to 10, wherein the first cathode material and the second cathode material are blended to form a blended cathode material that can be integrated into the battery cell structure.

[0097] In Example 12, the battery cell as described in any one of Examples 8 to 11, wherein the battery cell includes an electrode stack, and the battery cell structure is an electrode that can be integrated into the electrode stack of the battery cell.

[0098] In Example 13, the battery as described in any one of Examples 8 to 12, wherein the electrode is a coated electrode coated with the blended positive electrode material.

[0099] In Example 14, the battery cell as described in any one of Examples 8 to 13 further includes a protective coating on the positive electrode particles for reducing degradation during variable-speed reactions.

[0100] In Example 15, the battery cell is as described in any one of Examples 8 to 14, wherein the battery cell is modularly interconnected with one of a plurality of similar battery cells in the battery pack.

[0101] In Example 16, a battery pack having a hybrid chemistry system includes: a plurality of battery cells, each battery cell including a positive electrode having a blend of at least two active materials configured for a multiphase reaction with a variable discharge rate, the at least two active materials being similar materials; a battery management system (BMS) configured to monitor and balance the variable-rate reaction between battery cells; a thermal management system for regulating temperature during operation; and an electrical interconnect structure configured to support the multiphase reaction kinetics of the battery cells.

[0102] In Example 17, the battery pack is as described in Example 16, wherein the battery cells comprise a blend of LMFP materials.

[0103] In Example 18, the battery pack as described in Example 16 or 17, wherein the blend of LMFP materials includes a first cathode material and a second cathode material, the first cathode material and the second cathode material being a blend of iron and manganese.

[0104] In Example 19, the battery pack as described in any one of Examples 16 to 18, wherein the first positive electrode material has a higher iron content than the second positive electrode material.

[0105] In Example 20, the battery pack as described in any one of Examples 16 to 19, wherein the ratio of iron to manganese in the first positive electrode material is 6:4 or 7:3.

[0106] Real-world examples

[0107] The following practical examples illustrate representative implementations of the hybrid chemistry LMFP battery systems, structures, and processing technologies described in this specification. These examples are non-limiting and intended to illustrate how the principles of the invention (including blended LMFP cathode chemistry, multiphase reaction management, electrode-level integration, and battery pack-level operational control) can be applied in manufacturing and operation. Each example corresponds to... Figures 1A to 3C At least one of the conceptual scenarios depicted includes material-level blending (Scenario A), cell-level component integration (Scenario B), and cell-level or pack-level assembly (Scenario C). In practice, these instances can be implemented individually or in any suitable combination, depending on performance objectives, cost objectives, or safety constraints.

[0108] Example 1 - Material-grade blended LMFP cathode (Scenario A)

[0109] In this example, two LMFP compositions with different Fe:Mn ratios (e.g., 6:4 and 5:5) were blended at the material level prior to electrode fabrication. Figure 2A As illustrated, the first LMFP material, with a higher Fe content, contributes to a smoother initial voltage slope, while the second LMFP material exhibits a more pronounced manganese-driven plateau. The two powders are combined using high-energy ball milling at a predetermined mass ratio (e.g., 1:1 or 2:1) to ensure a uniform particle distribution. After blending, the cathode material is processed into a slurry with conductive carbon and a binder, which is then coated onto an aluminum current collector, dried, and rolled. Compared to the single-phase LMFP material, the blended electrode exhibits a more moderate two-phase voltage jump, improving SOC estimation during operation. Electrochemical testing confirms that the blended cathode retains the inherent safety and cycle life advantages of LMFPs while providing improved control characteristics for the BMS algorithm.

[0110] Example 2 - Dual Positive Electrode Stack Structure (Scenario B)

[0111] This example corresponds to cell-level hybridization, where two different positive electrodes (each made of different LMFPs) are combined into a phase-one electrode stack, such as... Figure 2A As shown. Instead of blending powders before coating, each positive electrode is coated with its own LMFP chemistry (e.g., Fe:Mn=6:4 and Fe:Mn=5:5), resulting in two electrodes with complementary voltage profiles. During cell stacking, the electrodes are arranged in an alternating sequence with the negative electrode layer and separator. Because the reaction rates of each positive electrode chemistry are slightly different, the resulting stack exhibits a broadened and smoother voltage range during discharge. This method allows manufacturers to utilize existing electrode coating production lines without modifying the material blending process. After assembly, the electrode stack is compressed, inserted into a pouch, wetted with electrolyte, and sealed. Formation cycling activates the combined reaction profiles between the two chemistry systems, producing enhanced ramp performance while maintaining thermal stability.

[0112] Example 3 - Battery Pack with Hybrid LMFP Chemistry System at the Cell Level (Scenario C)

[0113] In this battery pack-level example, individual pouch cell cells are fabricated using a single chemical system LMFP material, such that one subset of the cell cells uses a first Fe:Mn ratio (e.g., 6:4) while another subset uses a second ratio (e.g., 5:5). Figure 2BThe depicted system integrates two cell types into the same battery pack, arranged in a configurable series-parallel architecture. The Battery Management System (BMS) monitors the voltage, temperature, and impedance of each cell, identifying characteristic differences between the two chemical systems. During operation, a pack-level control algorithm dynamically allocates power demand among the cell subgroups to smooth out significant pack-level voltage jumps. For example, cells with faster reaction kinetics can receive higher current loads during transient demand periods, while utilizing cells exhibiting slower but more stable multiphase kinetics during steady-state cruise. This division of labor improves the accuracy of pack-level SOC estimation, mitigates voltage plateaus, and enhances overall energy management control without requiring material-level blending or electrode modification.

[0114] Example 4 - Blended positive electrode for high-power heavy-duty EVs

[0115] This example applies a blended LMFP cathode chemistry to a heavy-duty electric truck battery system, leveraging the outstanding thermal stability and long cycle life of this disclosure. Blended LMFP cathodes (e.g., 3:1 blends of 5:5 and 6:4) are chosen to provide a smoother voltage profile at high discharge rates, such as during sustained hill climbing or regenerative braking. Electrodes are fabricated using a high-load-capacity slurry formulation to increase the density of active materials without compromising structural integrity. The resulting cells exhibit improved controllability during the rapid SOC swings of a typical heavy-duty driving cycle. The battery pack integration includes a liquid cooling plate and distributed temperature sensors, allowing the BMS to maintain operational integrity regardless of multiphase reactions at elevated temperatures. Testing in a simulated Class 8 truck cycle confirms the reduced thermal bias and improved predictive SOC model, validating the benefits of blended LMFPs in high-power applications.

[0116] Example 5 - Adaptive BMS control for multiphase LMFP reactions

[0117] This example illustrates an operational method for managing multiphase LMFP reactions during cycling. A single cell is constructed using a blended LMFP cathode material or a dual-chemistry electrode stack as described above. During discharge, the BMS detects the characteristic voltage inflection point associated with the two-phase transition of the LMFP (see reference). Figure 1A and Figure 1B This describes the stepped voltage behavior and the blending smoothing effect. The BMS employs an adaptive state estimation algorithm that considers the variable diffusion rate and reaction rate between the constituent LMFP phases. When entering the voltage plateau region, the BMS increases the sampling frequency, applies a reaction phase-aware SOC model, and can temporarily adjust the current limit to maintain operational integrity. This adaptive control reduces SOC error accumulation and improves long-term SOH determination. In fleet applications, such improved accuracy reduces battery pack imbalance, extends maintenance intervals, and enhances charge profile optimization.

[0118] guide

[0119] The following guidelines are provided to support a clear understanding, consistent interpretation, and practical implementation of the embodiments described in this disclosure. These guidelines establish conventions applicable to LMFP hybrid chemistry battery systems described herein, clarify how to interpret figures and material references, and outline the intended breadth and flexibility of the principles of the invention. Unless explicitly stated otherwise, the figures are schematic and not drawn to scale; for clarity, electrochemical curves (including voltage curves) are idealized, and references to material composition, proportions, or reaction behavior include known variations and equivalents. The cathode materials, electrode structures, and cell-to-pack assemblies described are illustrative rather than limiting, and the concepts of the invention extend to modifications and combinations that will be apparent to those skilled in the art.

[0120] Detailed embodiments of this disclosure are disclosed herein as needed; however, it should be understood that the disclosed embodiments are merely exemplary embodiments of this disclosure and may be implemented in various alternative forms. The figures are not necessarily drawn to scale. Some features may be exaggerated or minimized to show detail of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to employ the contents of this disclosure in various ways.

[0121] The foregoing disclosure provides illustration and description, but is not intended to be exhaustive or to limit the implementation to the precise forms disclosed. Modifications can be made based on the foregoing disclosure, or modifications can be derived from practice of the implementation. As used herein, the term "component" is intended to be broadly interpreted as hardware, firmware, or a combination of hardware and software. It will be apparent that the systems and / or methods described herein can be implemented in various forms of hardware, firmware, and / or combinations of hardware and software. The actual dedicated control hardware or software code used to implement these systems and / or methods is not a limitation on the implementation. Therefore, the operation and behavior of the systems and / or methods are described herein without reference to any specific software code—it should be understood that the systems and / or methods can be implemented using software and hardware based on the description herein. As used herein, satisfying a threshold can, depending on the context, mean a value greater than, greater than or equal to, less than, less than or equal to, equal to, etc., depending on the context. Although specific combinations of features are listed in the claims and / or disclosed in the specification, these combinations are not intended to limit the disclosure of the various implementations. In fact, many of these features can be combined in ways not specifically listed in the claims and / or disclosed in the specification.

[0122] Although each dependent claim listed below may directly depend on only one claim, the disclosure of the various embodiments includes each dependent claim in combination with all other claims in the claim set. Elements, actions, or instructions used herein should not be construed as critical or essential unless explicitly described as such. Furthermore, as used herein, the articles “a” and “an” are intended to include one or more items and may be used interchangeably with “one or more.” Furthermore, as used herein, the article “the” is intended to include one or more items associated with the article “the” and may be used interchangeably with “the one or more.” Furthermore, as used herein, the term “set” is intended to include one or more items (e.g., related items, unrelated items, a combination of related and unrelated items, etc.) and may be used interchangeably with “one or more.” Where only one item is intended to be used, the phrase “only one” or similar language is used. Furthermore, as used herein, the terms “has,” “have,” “having,” or similar terms are intended to be open-ended terms. Additionally, the phrase “based on” is intended to mean “at least partially based on,” unless otherwise explicitly stated. Furthermore, as used herein, the term “or,” when used in series, is intended to be inclusive and may be used interchangeably with “and / or,” unless otherwise explicitly stated (e.g., if used in combination with “any” or “only one of…”).

[0123] Explanation and equivalence

[0124] The embodiments described herein are illustrative and not limiting. The structural and functional features disclosed in any embodiment may be combined, substituted, or rearranged with features of other embodiments unless explicitly stated otherwise. Graphs illustrating LMFP discharge profiles, blend behavior, or process sequences (e.g., Figures 1A to 3C The figures are provided for illustrative purposes and do not necessarily represent precise operating values ​​or scaling relationships. Relative dimensions, scales, electrode layer counts, and material ratios are illustrative unless otherwise indicated and may vary depending on manufacturing constraints or target battery performance.

[0125] Terms such as “assembly,” “arrangement,” or “component” include one or more parts unless the context clearly indicates a singular interpretation. Terms such as “configured as,” “arranged as,” “suited for,” and “constructed as” refer to functional capabilities and do not require any specific mechanism, manufacturing process, or material formulation. Therefore, the inventive concepts disclosed herein should be interpreted as describing relationships between structures, electrochemical functions, and system-level behavior, rather than specific geometric forms or limiting compositions. Equivalent substitutions, design alternatives, control strategies, and process variations that achieve substantially similar technical effects are all within the scope of this disclosure.

[0126] Explanation of range and size

[0127] All ranges and values ​​disclosed herein (including cathode material proportions, electrode thickness, porosity levels, roll density, state of charge (SOC) increments, and voltage jump widths) should be understood to allow for reasonable variations, manufacturing tolerances, and equivalents recognized in the art. Unless otherwise stated, the term "about" when associated with numerical values ​​indicates a variation within ±10% of the referenced quantity.

[0128] When ranges are provided (e.g., "1:1 to 3:1 blending ratio", "5-20 µm coating thickness", or "less than 5% interphase voltage deviation"), such ranges encompass all subranges and increments thereof, including all equivalents that achieve similar electrochemical performance. Relative comparisons such as "higher Fe content", "wider voltage plateau", or "faster diffusion phase" will be interpreted relative to the referenced examples or materials.

[0129] The accompanying figures, flowcharts, and cross-sections are representative only. Actual layer thicknesses, electrode locations, and battery pack configurations can vary depending on fabrication tolerances, slurry formulations, coating equipment, stack alignment, or battery pack integration requirements. Features depicted as discrete can be fabricated integrally, and features illustrated as continuous may include joints, transitions, or interfaces (not shown for clarity).

[0130] Cross-applicability and functional breadth

[0131] While many embodiments focus on LMFP hybrid chemistry reactions, blended cathode formulations, or dual-electrode stack architectures, the principles of this invention can be applied to a wide range of lithium-ion systems and structures. These include cell-to-pack, cell-to-module-to-pack, blade-to-cell architectures, stationary storage modules, and hybrid EV / HEV energy storage platforms. Functional concepts such as smoothing multiphase voltage jumps, improving SOC estimation, integrating hybrid chemistry electrodes, or enabling pack-level balancing algorithms can be transferred to other chemistry systems with similar phase behavior.

[0132] The disclosed principles are compatible with applications in electric vehicles, commercial and heavy-duty drive systems, aerospace auxiliary units, marine propulsion, and stationary grid storage. Mechanisms that promote operational integrity (e.g., thermal stability, voltage jump smoothing, response rate coordination) and structural integrity (e.g., stable electrode interfaces, consistent mechanical lamination pressure) are broadly applicable to different system architectures.

[0133] Manufacturing flexibility

[0134] The structure and process of this invention are compatible with a variety of materials, coating methods, stacking arrangements, and cell forms. Although LMFP-LMFP blends are mainly discussed, equivalent functional behavior can be achieved by blending LMFP with other compatible phosphate chemistry systems, by using them in dual-electrode stacks, or by using them in battery packs of cells with mixed chemistry systems.

[0135] Electrode fabrication can employ blade coating, slot-die coating, gravure printing, or extrusion techniques. Roll density, binder chemistry, conductive additive loading, and solvent system can be customized based on the specific LMFP ratio or phase composition. Similarly, cell assembly can involve stacked (prismatic or pouch) or wound (cylindrical) forms.

[0136] Thermal management strategies, including liquid cooling plates, thermal foams, and phase change materials, can be selected based on the thermal properties of the blended LMFP phases. Automated manufacturing controls, such as online impedance checking, vision-based electrode inspection, or formation cycle profiling, can be used to verify interphase consistency and multimodal reaction behavior.

[0137] Validation, inspection, and maintainability

[0138] Electrochemical, mechanical, thermal, or optical techniques, including impedance spectroscopy, X-ray or ultrasonic examination, thermal imaging, or accelerated cycling, can be used to validate individual cells or packs implementing the disclosed concepts. Validation may include confirming the co-phase reaction behavior, a smoother voltage jump region, a balanced diffusion response, and consistent SOC estimation under load.

[0139] Modular battery pack architecture allows for submodule-level verification and replacement without requiring complete pack disassembly. This modularity supports scalable manufacturing, fleet maintainability, and improved quality control by enabling partial rework of individual cells or modules containing co-chemical electrodes.

[0140] Therefore, the examples and embodiments described herein should be understood as illustrating flexible, scalable, and cross-applicable design principles consistent with the inventive concept of smoothing voltage jumps in multiphase LMFPs through material blending, electrode-level structuring, and battery pack-level control.

Claims

1. A method for manufacturing a hybrid chemical system battery, comprising: A first cathode material is provided, comprising a blend of multiple active materials, each of which contributes to a multiphase reaction with a variable voltage profile; A second cathode material is provided that is chemically compatible with the first cathode material, and the second cathode material is similar to the first cathode material; The first cathode material and the second cathode material are mixed to form a blended cathode material; The blended cathode material is used to form a battery cell structure that can be assembled into a battery cell. as well as The battery cell structure is assembled into a battery cell, which is then operatively integrated into a battery pack, the battery pack being controllable to address potential differences in the charging / discharging behavior between the first cathode material and the second cathode material.

2. The method according to claim 1, wherein the first cathode material and the second cathode material are various mixtures of lithium manganese iron phosphate (LMFP) materials.

3. The method according to claim 2, wherein the first cathode material and the second cathode material are a blend of iron and manganese, wherein the first cathode material has a higher iron content than the second cathode material.

4. The method of claim 1, wherein the multiphase reaction involves a first phase having a fast voltage curve and a second phase having a slower, sustained voltage curve.

5. The method of claim 1, wherein the cell structure is an electrode, and the step of forming the cell structure capable of being assembled into a cell using the blended cathode material includes integrating the blended cathode material into the electrode.

6. The method of claim 5, wherein integrating the blended cathode material into the electrode comprises coating the electrode with the blended cathode material to form a coated electrode.

7. The method of claim 6, wherein assembling the battery cell structure into a battery cell includes integrating the coated electrode into an electrode stack.

8. A battery cell with a mixed chemical system, comprising: A first cathode material, comprising a blend of at least two active materials, wherein the at least two active materials are configured for a multiphase reaction having a variable discharge rate; A second cathode material is designed to complement the chemical system of the first cathode material, and the second cathode material is similar to the first cathode material. as well as An electrolyte that promotes ionic conductivity between a positive electrode and a negative electrode, wherein the positive electrode comprises a first positive electrode material and a second positive electrode material.

9. The battery cell according to claim 8, wherein the first cathode material is a blended lithium manganese iron phosphate (LMFP) material.

10. The battery cell according to claim 8, wherein the first positive electrode material and the second positive electrode material are a blend of iron and manganese, wherein the first positive electrode material has a higher iron content than the second positive electrode material.

11. The battery cell of claim 8, wherein the first cathode material and the second cathode material are blended to form a blended cathode material capable of being integrated into the battery cell structure of the battery cell.

12. The battery cell of claim 11, wherein the battery cell comprises an electrode stack, and the battery cell structure is an electrode that can be integrated into the electrode stack of the battery cell.

13. The battery according to claim 12, wherein the electrode is a coated electrode coated with the blended positive electrode material.

14. The battery cell according to claim 8, wherein the electrode stack is formed by alternating layers of a first positive electrode, a second positive electrode, and a negative electrode, and a separator is placed between each positive electrode and the negative electrode.

15. The battery cell of claim 8, wherein the battery cell is modularly interconnected with one of a plurality of similar battery cells in a battery pack.

16. A battery pack having a mixed chemical system, comprising: Multiple battery cells, each battery cell including a positive electrode having a blend of at least two active materials, the at least two active materials being configured for a multiphase reaction with a variable discharge rate, the at least two active materials being similar materials; A battery management system (BMS) configured to monitor and balance the variable-speed response between the individual battery cells; A thermal management system for regulating temperature during operation; as well as An electrical interconnect structure configured to support the multiphase reaction dynamics of the battery cell.

17. The battery pack of claim 16, wherein the battery cell comprises a blend of LMFP material.

18. The battery pack of claim 17, wherein the blend of the LMFP material comprises a first positive electrode material and a second positive electrode material, wherein the first positive electrode material and the second positive electrode material are a blend of iron and manganese.

19. The battery pack of claim 18, wherein the first positive electrode material has a higher iron content than the second positive electrode material.

20. The battery pack according to claim 19, wherein the ratio of iron to manganese in the first positive electrode material is 6:4 or 7:3.

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